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Ajol File Journals - 483 - Articles - 123621 - Submission - Proof - 123621 5701 338107 1 10 20151009
Ajol File Journals - 483 - Articles - 123621 - Submission - Proof - 123621 5701 338107 1 10 20151009
Abstract
A motorized oil palm fruit rotary digester comprising of a feed hopper, hammers, axle, screening plate, v-v-belt,
2hp electric motor, digesting chamber and frame was designed and developed using standard and locally
sourced materials. The performance test analysis showed that its throughput capacity is 117.93kg/hr with a
performance efficiency of 64.88% at an optimum operational speed of 621.4rpm. Rate of digestion increased
with the mass of the digesting palm fruit while the efficiency of the oil palm fruit digesting machine decreased
with increase in mass of the digesting palm fruit in some cases.
81,475 and 105,184 ha, respectively. Red palm oil, that the various oil palm products like edible oil,
the most important product of the oil palm, is the soap, confectioneries etc can be derived. Figure 2
world’s main edible oil also used for soap making [6]. gives a cross sectional diagramme of oil palm fruit.
It is used for soup and table fats such as margarine
and for the production of cosmetics in many
countries as well as useful raw material in
pharmaceutical industries for the manufacture of
drugs. Red palm oil is used in the manufacturing of
soap, toiletries, surface active ingredients, baking
coatings, whipped creams and sugar confectioneries.
The meal obtained after oil extraction from the palm
kernel nut is also used as animal feed. High quality
palm oil is needed for domestic and industrial
applications. Two types of oil are produced from the Figure 2: Fresh palm fruit
oil palm, red palm oil from the fruit white oil from Digestion is the process of releasing the palm oil in
the kernel. The palm oil content of the fruit is about the fruit through the rupture or breaking down of the
55% and of the kernel is about 47% [7]. The fatty oil-bearing cells. The digester commonly used
acid composition of the palm oil is very different consists of a steam-heated cylindrical vessel fitted
from that of the palm kernel oil. Typically, for tenera with a central rotating shaft carrying a number of
fruit, 100 tones of fresh fruit bunches will yield 21 beater (stirring) arms. Through the action of the
tonnes of oil and 6 tonnes of decorticated palm rotating beater arms the fruit is pounded. Pounding,
kernel oil. This palm kernel oil represents 12% of or digesting the fruit at high temperature, helps to
total oil production. reduce the viscosity of the oil, destroys the fruits’
Figure 1 below shows the block diagram of the outer covering (exocarp), and completes the
processes in oil palm production. disruption of the oil cells already begun in the
sterilization phase. Unfortunately, for reasons
related to cost and maintenance, most small-scale
digesters do not have the heat insulation and steam
injections that help to maintain their contents at
elevated temperatures during this operation.
Farmers and oil palm processors carry out the
process of oil palm fruit digestion by manual means.
Local, digestion of palm fruit is usually performed by
the use of mortar and pestle or by barefoot
processing method. In the mortar and pestle method,
the boiled palm fruits are poured into the wooden
mortar. The mortar is surrounded by villagers,
mostly women, who take turns to pound/pulp the
fruits using pestles. The amount or quality of palm
fruits to be digested or pulped depends on the size of
the mortar and the strength of the women. On the
other hand, the barefoot processing method is quite
Source: [5] similar to the mortar and pestle method, but in this
Figure 1: Block diagram showing major stages involved case, the pulping chamber is a wooded canoe and the
in oil palm production pestle is the bare foot. These primitive methods of
digestions have a wide range of disadvantages, some
From the above block diagram, the key process in the of which are: slow and very low digestion and
oil palm production process is fruit production rates, unhygienic, time-consuming,
pulping/digestion. Fruit pulping/digestion, which is drudgery and the fact that a lot of human energy is
taken as the fifth step in the block diagram above, usually expended during pulping/digestion. Due to
involves the digesting of the boiled or unboiled mass this poor processing method, countries like Nigeria
of palm fruit in such a manner that its mesocarp (the have not been able to fully utilize the product export
fleshly part of the palm fruit) is separated from the capacity.
kernel. This step is important in the sense that, it is On the other hand, the mechanized form of palm oil
only when the fruits have been thoroughly pulped processing which embodies to some extent the small
Nigerian Journal of Technology Vol. 32, No. 3, November 2013 456
DEVELOPMENT OF MOTORIZED OIL PALM FRUIT ROTARY DIGESTER, F. U. Asoiro, U. C. Udo
and large scale mills may involve series of vertically with the top opening which a hopper was
mechanized and automated system tending to serve attached to serve as the door way to the digesting
the purpose of each major stage or process along the chamber. The bottom part is closed with a conical
production line of which oil palm fruit digestion is flange having a central opening of 25mm that will aid
one. Thus, one of the constrains in the mechanization the collection of oil after digestion. It is made of
and automation of small-scale palm oil mills is the 3.5mm stainless steel sheet with a diameter of
unavailability of an efficient, small scale palm fruit 455mm and a height of 380mm.
digester of which this work chooses to address.
2.2.4 The Hammer
2. Materials and Method This is designed to act as beaters. They are attached
2.1 Design Consideration and Specifications to a central shaft to provide the size reduction effect
Having studied the primitive method of digestion on the palm fruit. On the other side of it a pulley is
and mechanized rotary action oil palm fruit digester, fitted to the hammer shaft to provide the drive from
a lot was taken into consideration in the the electric motor via the v-belt. The hammers are
development of the machine: eight in number. They are made of 37.5 × 37.5 × 500
1. Higher capacity compared to the traditional mm angle iron.
/primitive method of palm fruit digestion.
2. Reduction in drudgery associated with the 2.3
2.3 Description of the Machine
traditional/primitive method of palm fruit The developed palm fruit digester (Figure 3) was
digestion. designed, fabricated and assembled at the workshop
3. Strength of material should withstand the force of Agricultural and Bioresources Engineering,
acting on the various components of the rotary University of Nigeria, Nsukka.. The machine consists
palm fruit digester. of a hopper, frame, digesting chamber and hammers
4. Simplicity and complexity of the digester should enclosed in the digesting chamber.
suit the intended user(s) and has no side effect on Cooked or uncooked palm fruit is fed through a
him and his environment. hopper which is trapezoidal in shape, made of 3.5
5. The angle of inclination for the hopper was 45o to stainless steel, welded at an angle of repose of 45o to
the horizontal which was the angle of repose of an orifice that empties into the digesting chamber. In
the variety of palm fruit on stainless steel the digesting chamber are eight sets of hammers
determined in the laboratory. attached to a centrally placed vertical shaft. As the
hammers rotate, they help in the pulping/digestion
2.2 Machine Features of the palm fruits. On the end side of the hammer
2.2.1 Hopper shaft, a pulley is fitted to the hammer shaft to
The hopper is made up of 3.5mm gauge stainless provide the drive from the electric motor of 3 horse
steel sheet. The shape of the hopper is trapezoidal power via the v-belt. The shaft is made up of 24mm
and also provides a doorway to the digesting gauge stainless steel. The electric motor revolves at
chamber. The hopper is mounted on top of the 621.4rpm with belt and pulley connections.
digesting chamber and has a semi-circular shape at
the throat region for easy flow of the palm fruit. The 2.3 Machine Component Selection and Design
design is based on the angle of repose of 45o of palm Calculations
fruit on stainless steel which is determined for the 2.3.1 Determination of Physical and Mechanical
dura, tenera and pisifera species. Properties of Oil Palm Fruit
For effective design of the machine, it was necessary
2.2.2 Frame to determine the physical and mechanical properties
The frame provides rigid and skeletal support for the of the oil palm fruits relevant to their behaviour
entire system. Apart from the four-corner support of during pulping. The physical properties that were
main frame work, it consists of two compartments, considered in this study are size, shape, true density,
which are the support for the digesting chamber and bulk density and porosity while the mechanical
another support for the electric motor. The frame is properties are hardness and shear strength. These
made of 2 inch angle iron bar. It has a length of experiments were carried out in Agricultural and
655mm, width 655mm and height of 400mm. Bioresources Engineering and civil Engineering
2.2.3 Digesting Chamber Laboratories, University of Nigeria Nsukka.
This is set to provide housing for the hammers
during operation. It is a cylindrical drum placed
• Determination of size
From the samples, 50 fruits were selected at random
for determining the physical characteristics. For
each fruit, three linear dimensions were measured,
that is (a) length, (b) width, and (c) thickness, using
a Vernier caliper (Kanon Instrument, Japan) reading
to 0.01 mm. Hence measurement of all size indices
were replicated three times
• Determination of shape
The fruit shape was expressed in terms of its
sphericity index and aspect ratio. For the sphericity
index (Sc), the dimensions obtained for the 50 palm
fruits selected at random in above were used to
compute the index based on equation (1) [8].
1
3
(abc)
Sc = × 100 (1)
a (c)
where a is the major diameter (mm), b is the
intermediate diameter (mm), c is the minor
diameter (mm) and S c is the sphericity index.
(d)
2
2πN 2 Fc
T2= (20)
Fc = M r1 (12)
3
60
Effective tension on the belt then becomes 81.3N.
Centrifugal force developed in the beater was then
obtained from (12) as 122N.
2. Shaft Selection
The machine shaft was selected using the code of
3. Torque Developed
America Society of Mechanical Engineers (ASME)
The torque in the design is considered here so that
equation for solid shaft having little or no axial
the idea of the capacity or power of the electric
loading shown in (21).
motor to be used can be determined. Using the
Where,
expression by Kurmi and Gupta [15] that torque (T)
16 1
is equal to the product of force and radius, the value
of the torque developed on the pulley of the hammer
d3=
πS s
[
( K b M b )2 + ( K t M t )2 ] 2
(21)
shaft can be calculated using: where d is the diameter of shaft (m), Ss is the
T=Fcr2 (13) ultimate stress of mild steel without key way (= 55
Where Fc id the centrifugal force developed in the N/m2 ), Kb is the combined shock and fatigue factor
barrel, r2 is the radius of pulley on the hammer shaft. applied to bending, moment is 1.5, Mb is the
So the torque developed in the system will be maximum bending moment (Nm), Kt is the combined
8.57Nm. shock and fatigue factor applied torsional moment
(=1.0) and Mt is the maximum torsion moment (Nm)
2.3.3. Power Requirement, Tension in the Belt and
Shaft Selection 2.4 Performance Test Procedures.
The power requirement of the machine was 2.4.1 Sourcing and Preparation of the Test Sample
determined with the expression by Kurmi and Gupta A bulk sample of matured palm fruit (dura specie) of
[15] which states that power is the product of torque about 240kg was procured from the main market,
(T) and angular velocity ( ω ) as: Nsukka, Enugu State, Nigeria. The palm fruit was
P = Tω (14) inspected to ascertain its quality. The fruits were
2πN 2 cleansed and washed for dirt and other
But ω = , therefore (14) becomes: contaminants. Samples were collected to determine
60
the initial moisture content. After the digester has
2πN 2T
P= (15) been assembled and installed, two different sets of
60 experiments were carried out using the oil palm
where P is the Power (Watt) , N is the speed of shaft fruits. In the first experimental plan, the optimal
(r.p.m) and T is the torque required to turn the shaft speed of the digester was determined. Ten different
(Nm). Therefore 2hp was selected to give the samples of boiled fresh oil palm fruit weighing 5kg
required torque in the system. each was fed through the hopper for digesting after
starting the machine. In each of the ten trails with
1. Tension in the V-belt different operational speed of 581.4, 591.4, 601.4,
Tension in the v-belt was deduced by applying Kurmi 611.4, 621.4, 631.4, 641.4, 651.4, 661.4 and
and Gupta [15] formula shown in equation (15) 671.4rpm, a stop watch was used to monitor the time
T1 taken for the digestion
= l θµ (16)
In the second experiment, the performance of the
T2
digester was evaluated by determining the rate of
where T1 is the tension on the tight side of the belt,
digestion, DC (Kg/hr) and efficiency, η (%).
T2 is the tension on the slack side of the belt, µ is the
coefficient of friction and θ is the angle of wrap in W
Dc = × 60 (22)
radians. Ta
But for v-belts where, DC is the rate of digestion (kg/hr) and Ta is
T1 the average digestion time (mins).
=3 (17)
T2 Wd
η= × 100 (23)
Where the factor 3 is a constant for v-belts W
Therefore, T1 =3T2 (18) Where, η is the efficiency(%), Wd is the weight of the
Since T1 = Fc (19) digested fruit collected at the outlet of the digester
Therefore, (kg) and W is the initial weight of the palm fruit fed
Nigerian Journal of Technology Vol. 32, No. 3, November 2013 460
DEVELOPMENT OF MOTORIZED OIL PALM FRUIT ROTARY DIGESTER, F. U. Asoiro, U. C. Udo
into the digester(kg). Twenty different samples of The developed oil palm fruit digester was found to
fresh palm fruit of weight 10, 15, 20, 25, 30, 35, 40, perform satisfactorily with all the mass of the fresh
45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 100 and palm fruit poured into it at constant operational
105kg were fed through the hopper of the digester at speed of 621.4rpm when tested. The highest
an optimal operational speed of 621.4rpm. A stop digesting efficiency of 71.73% with a digesting
watch was used to record the digestion time taken capacity of 143.31kg/hr was obtained when an
for each of the twenty trials. initial palm fruit mass of 75kg was digested. The
amount of digested and undigested fruit produced
3. Results and Discussion from this are 53.8kg and 21.2kg respectively. The
Data from the first experiment shown in Table 1 digester capacity could be increased for large scale
showed that the optimal speed of the digester is digestion of palm fruits.
621.4rpm. This is because from the speed of
621.4rpm upwards, the digestion time is almost the Table 1: Determination of optimal speed of oil palm
same. Table 1 also showed that as the speed fruit digester for a fruit weighing 5grams.
increases, the digestion time decreases. S/n Speed (rpm) Time of digestion mins)
The digester performance result presented in Table 1 581.4 8.50
2 shows that the digesting capacity, Dc and efficiency, 2 591.4 7.60
η are 117.93kg/hr and 64.88% respectively. 3 601.4 6.70
4 611.4 5.8
Expectedly, increase in mass of the palm fruit
5 621.4 4.98
increases the digestion time and the digesting 6 631.4 4.98
capacity of the digester. In some cases, the efficiency 7 641.4 4.98
of the palm fruit digester, increases with increase in 8 651.4 4.97
the mass of the palm fruit, while in most cases there 9 661.4 4.97
is a significant increase in the efficiency of the oil 10 671.4 4.96
palm fruit rotary digester. This agrees with an earlier
design Ugoamadi [16] for cassava pelleting machine .
Table 2: Determination of digesting capacity and efficiency of the developed rotary oil palm fruit digester.
Initial weight of Weight of Weight of Average Average Digesting Efficienc
Te palm fruit, digested fruit, undigested fruit, digestion time, digestion time, capacity, y, η
st W(kg) Wd(kg) Wu(kg) Ta(min) Ta(hrs) Dc(kg/h) (%)
1 10.00 5.20 4.80 6.80 0.11 88.24 52.00
2 15.00 8.80 6.20 10.80 0.18 83.33 58.67
3 20.00 10.20 8.80 12.30 0.21 97.56 53.68
4 25.00 12.90 12.10 14.30 0.24 104.90 51.60
5 30.00 16.90 13.10 14.80 0.25 121.62 56.33
6 35.00 21.50 13.50 16.90 0.28 124.26 61.43
7 40.00 26.00 14.00 20.10 0.34 119.40 65.00
8 45.00 30.30 14.70 21.90 0.37 123.29 67.33
9 50.00 33.70 16.30 24.20 0.40 123.97 67.40
10 55.00 38.10 16.90 23.10 0.39 142.86 69.27
11 60.00 43.00 17.00 25.90 0.43 139.00 71.67
12 65.00 47.00 18.00 29.20 0.49 133.56 72.31
13 70.00 50.10 19.90 30.20 0.50 139.07 71.57
14 75.00 53.80 21.20 31.40 0.52 143.31 71.73
15 80.00 57.00 23.00 38.90 0.65 123.39 71.25
16 85.00 59.20 25.80 40.20 0.67 126.87 69.65
17 90.00 60.50 29.50 44.30 0.74 121.90 67.22
18 95.00 63.20 31.80 50.60 0.84 112.65 66.53
19 100.00 66.20 33.80 60.10 1.00 99.83 66.20
20 105.00 70.10 34.90 70.30 1.17 89.62 66.76
4. Conclusion and Recommendation Published in part 2, Oleagineux, 28, Annee, No. 12,
4.1 Conclusion 2003.
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